JP2008545562A - Surface-treated elastomer film having a coating layer for preventing roll blocking - Google Patents

Abstract

  A non-blocking coated elastomer film comprising an elastomer polymer film layer and a non-blocking solvent-based coating layer. The coating layer includes a non-blocking coating component. The coating layer is coated on one or both sides of the elastomer polymer film layer.

Description

  The present invention relates to a non-blocking painted elastomer film, and also relates to a method for producing a non-blocking painted elastomer film.

  Elastomeric materials have long been appreciated for their ability to expand and fit over or around a large object and then shrink to fit snugly to the object. In recent years, synthetic polymer elastomeric materials have compensated for or replaced the shortage of natural rubber. Compounds such as polyurethane rubbers, styrene block copolymers, ethylene propylene rubbers, and other synthetic polymer elastomers are well known in the art.

  The elastomeric material can take a variety of shapes. Elastomers can be formed as yarns, cords, tapes, films, fibers, and various other forms. The shape and structure of the elastomeric material depends on the intended end use of the product. For example, elastomers are often used in garments such as active clothing to provide a snug fit. Elastomers can also form elastic but effective barriers, such as in cold clothing cuffs intended to maintain body heat. In these applications, the elastomer is most often in the form of yarns or filaments that are incorporated into clothing fabrics.

  The elastomer can be in the form of a yarn, fabric or film. Since elastomeric yarns must be applied as one of a number of components in the manufacturing process, the use of these yarns presents problems when assembling garments. In addition, these yarns are weak and easily broken, and even if the yarn is excessive, elastic failure occurs. Elastomeric fabrics are somewhat easier to work with in the manufacturing process, but the fabrics themselves tend to be expensive both in the raw materials and the cost of manufacturing the fabrics themselves. Elastomer films are easier to use than yarn and are less expensive to manufacture than elastomeric fabrics. In addition, elastomer films tend to be stronger than yarns or fabrics and are not easily damaged during use.

  However, the inconvenience of elastomeric films is that the polymers used to make the films are inherently sticky or sticky. When these elastomeric films are extruded and wound into rolls, the elastomeric films themselves tend to stick or “block”, which makes it difficult or impossible to unwind. When the film is aged or stored in a warm environment such as in a storage, blocking becomes more pronounced.

  Many attempts have been made to solve the blocking problem of elastomeric films. Usually, an antiblocking agent which is a powdery inorganic substance such as silica or talc can be blended in the film. Moreover, an antiblocking agent can be sprinkled on the outer surface at the time of shaping | molding of an extrusion film. However, in order to reduce blocking to an acceptable level, large amounts of antiblocking agents must be added, but these high levels of blocking resistance are detrimental to the elastic properties of the film. Another means of reducing blocking is to roughen the film surface, such as by embossing the film, to reduce the surface-to-surface contact of the take-up film and to help reduce blocking. The introduction of fine air pockets. Unfortunately, this method also tends to produce thinner and weaker portions of the film that are subject to cracks and breaks as the film is stretched. Another means of reducing blocking is to incorporate a physical barrier, such as a release liner, into the roll between the layers of the take-up film. The release liner is then removed when the wound film is rewound for further processing. Although release liners are usually discarded, they incur significant extra costs for waste and manufacturers. Yet another means of reducing blocking of the elastomeric film is to apply a very thin outer layer, also called a “skin” or “capping layer”, of a stretchable or less elastic non-sticky polymer to the surface of the elastomeric film. Co-extrusion. Suitable non-sticky polymers for these coatings include polyolefins such as polyethylene and polypropylene. Such a polyolefin film is extensible but not an elastomeric material. Since the polyolefin film constitutes a small portion of the total composition of the elastomer film, the polyolefin film as a whole has little influence on the elastomeric properties of the film. However, these polyolefin films stretch and deform irreversibly when the elastomeric film is stretched as a whole and is first “activated”. When the stretching force on the activated elastomeric film is released, the elastomeric core portion tends to shrink as usual. The stretched film is not elastomeric and instead wrinkles and creates a microstructured surface as the core shrinks.

  There remains a need to effectively produce an elastomeric film that can be wound and stored without blocking. Such a film should not have inferior elastomeric properties, generate excessive waste and manufacturing expense, and should provide an attractive and pleasant surface texture after activation.

  In one embodiment, the present invention relates to a non-blocking elastomeric film. The non-blocking elastomer film comprises an elastomer polymer film layer and a non-blocking solvent-based coating layer containing a non-blocking coating component. The non-blocking coating layer is applied to one or both sides of the elastomer polymer film layer to make the elastomer film non-blocking.

  In another aspect, the present invention relates to a method for producing a non-blocking elastomeric film. The manufacturing method consists of coating the first surface of an elastomeric polymer film with a non-blocking solvent-based coating containing a non-blocking coating component. One side or both sides of the elastomer polymer film layer can be coated to form a non-blocking elastomer film.

  Additional aspects of the invention will become apparent from the following detailed description of the invention.

  We remove roll blocking by extrusion by applying a thin coating such as lacquer, lubricant, surfactant or slurry on one or both sides of the elastomeric film after extrusion and before winding, It was found that it can be reduced to an acceptable level. Although it is necessary to paint only on one side of the elastomer film, it may be applied on the other film surface as desired. The elastomeric film can be wound and stored after this surface coating without significant roll blocking. Unexpectedly, the coating does not interfere or interfere with the lamination of other layers, such as nonwovens, to the painted surface of the elastomeric film.

  For purposes of this disclosure, the following terms are defined as follows:

  “Film” refers to a sheet-like material in which the dimension of the material in the x (length) and y (width) directions is substantially larger than the dimension in the z (thickness) direction. The film has a z-direction thickness ranging from about 1 μm to about 1 mm.

  “Laminate” as a noun is a layered structure of sheet-like materials that are stacked and joined so that each layer is substantially coextensive over the width of the narrowest sheet material Say. These layers consist of films, fabrics or other materials in sheet form, or combinations thereof. For example, a laminate is a structure consisting of a layer of film and a layer of fabric joined together across their widths so that the two layers remain joined as a single sheet under normal use. It can be. The laminate can also be referred to as a composite or a coating material. “Laminate” as a verb refers to a method of forming such a layered structure.

  “Coating” refers to a solvent-based solution or suspension capable of applying a thin layer to the surface of a material. The term “coating” refers to a thin layer of material that has been applied to the surface and has been substantially dried or cured. For the purposes of this disclosure, a coating refers to a material layer that is about 0.05-3 μm thick. For purposes of this disclosure, the coating may consist of spaced-apart paint areas, for example in the form of dots, separated by non-painted surface areas. Alternatively, the coating may consist of a substantially continuous coating layer surrounded by discontinuous areas of the non-painted surface. Alternatively, the coating may consist of a substantially continuous painted area with substantially no unpainted surface area.

  “Solvent” or “carrier solvent” refers to a liquid in which a material is dissolved or suspended. For the purposes of this disclosure, “solvent” or “carrier solvent” refers to the liquid in which the coating material is dissolved or suspended, unless the term is used in the context of other solutions or solvents. (Including both aqueous and organic liquids). Exemplary solvents used in the coatings discussed in this disclosure can include, but are not limited to, water, isopropyl alcohol, hexane, ethyl acetate, or other such common solvents.

  “Ink” refers to a mixture of a pigment, a binder, and a carrier solvent that can be applied to the surface of a material as a coating. The ink can be used to display a whitening agent, opacifying agent, coloring, graph, image, design, text, or other mark on the surface of the material. The ink is typically applied as a thin layer on the surface of the material by a printing method, although other coating methods can be used. After painting, the ink is dried by evaporation or oxidation of the carrier solvent to form a coating film. Suitable inks include companies such as Flint Ink of Ann Arbor, Michigan, INX International Ink Co. of Schaumburg, Ill., Or Sun Chemical of Persipany, NJ Can be obtained from

  “Lacquer” refers to a solution of a material that forms a coating on the material to provide a glossy, modified, and / or protective surface. Lacquers may or may not be colored and are made of natural or synthetic resins. Common resins used in synthetic lacquers are piroxylin or nitrocellulose, which is dissolved in a carrier solvent and optionally contains plasticizers, pigments and other components. The lacquer is applied to the surface by printing, spraying, painting, dip coating, and other methods. After coating, it is dried by evaporation of the carrier solvent and / or oxidation of the resin to form a coating film. Suitable are available from companies such as Flint Inc. of Ann Arbor, Michigan and Sun Chemical Co. of Persipany, NJ.

  “Surfactant” refers to a chemical substance that reduces the surface tension of a carrier solvent in which the surfactant is dissolved. Most commonly, the carrier solvent is usually liquid water with a high surface tension. By reducing the surface tension of the solvent (eg, water), the surfactant allows the solution to wet faster and diffuse to the surface. Most surfactants have an amphiphilic chemistry with a hydrophobic chemistry at one “end” of the molecule and a hydrophilic chemistry at the “end” on the other side of the molecule. It is a substance. Common soaps and detergents as well as other cationic, anionic or nonionic surfactants are considered surfactants for purposes of this disclosure.

  “Lubricant” refers to a chemical that reduces friction between adjacent surfaces when applied on one or both sides. Common lubricants include oils, greases, and waxes. For purposes of this disclosure, the lubricant can be dissolved or suspended in a suitable carrier solvent such as a common organic solvent. Water based lubricants are also suitable for this disclosure. For example, a suitable water-based lubricant can be obtained as a POLYWATER® series of lubricants from American Polywater Corporation of Stillwater, Minnesota.

  A “slurry” or “suspension” is a mixture of a carrier solvent and a particulate solid that does not dissolve in the solvent but is substantially distributed in a large amount of the solvent. That is homogeneously mixed. Slurries and suspensions can vary in concentration from thin liquids of low concentration solids to thick pastes of high concentration solids. Examples of suitable slurries or suspensions include a mixture of inorganic powders such as calcium carbonate, talc, clay, or mica in a suitable carrier solvent such as water. Examples of other suitable slurries or suspensions may include a powder of an organic material such as starch or cellulose mixed in a suitable carrier solvent such as water. Other suitable slurries or suspensions can include polymer powders or particles mixed in a suitable carrier solvent such as isopropyl alcohol. A suitable polymer powder can be obtained from Equistar Chemicals LP, Houston, Texas, under the trade name MICROTHENE®.

  “Stretchable” and “recoverable” are descriptive terms for describing the elastomeric properties of a material. “Extensible” means that the material is stretched significantly greater than the original dimensions without breaking by a tensile force in a specific direction. For example, a 10 cm long material can be said to be extensible when it can be stretched to a length of about 15 cm without breaking by tensile force. “Recoverability” means that a material that has been stretched significantly larger than its original dimension without breaking due to a tensile force in a specific direction, when the tensile force is released, is that original dimension or a specific dimension that is sufficiently close to the original dimension It means to recover. For example, when a 10 cm long material stretches to a length of about 15 cm without breaking by tensile force and recovers to a length of about 10 cm or a specific length close enough to 10 cm, It can be said that there is.

  “Elastomeric” or “elastomer” refers to a weight that can be stretched to at least about 150% of its original dimensions in the direction of the applied tensile force and then shrinks to 120% or less of those original dimensions. This refers to the combined material. For example, a 10 cm long elastomeric film should stretch to at least about 15 cm under stretch and then shrink to about 12 cm or less when the stretch is removed. Elastomeric materials are extensible and recoverable.

  “Extensible” means that the material can be stretched to at least about 130% of its original dimensions without breaking, but does not recover significantly or recovers beyond about 120% of its original dimensions. Therefore, it means not elastomeric as defined above. For example, an extensible film that is 10 cm long is stretched to at least about 13 cm under stretching force and then remains about 13 cm long when the stretching force is released, or longer than about 12 cm. I will recover. An extensible material is extensible but not recoverable.

  By “brittle” is meant a polymeric material that has a strong resistance to stretching and cannot stretch more than 110% of its original dimensions without breaking or cracking. For example, a 10 cm long fragile film cannot be stretched beyond about 11 cm under stretching force without being crushed. A brittle film will not recover or only recover slightly when the stretching force is removed. A brittle material is neither stretchable nor recoverable.

  “Blocking” refers to the phenomenon of self-adhesion when wound on a roll, folded, or placed in close contact with a surface to surface due to its inherent tackiness or tackiness of one or more film components. means. Blocking can be quantified by ASTM D3354 “Plastic Film Blocking Load by Parallel Plate Method”.

  “Non-blocking” means a material that does not block when placed in intimate contact with itself.

  “Activation” or “activate” refers to a method of facilitating stretching of an elastomeric film or material. Most often the activation is a physical treatment, modification or deformation of the elastomeric film. Drawing a film for the first time is one means of activating the film. An elastomeric material that has undergone activation is referred to as "activated". A common example of activation is inflating a balloon. For the first time, when the balloon is inflated (“activated”), the balloon material is stretched. If the balloon material is difficult to stretch, the person inflating the balloon often stretches the uninflated balloon by hand, making it easier to inflate. If the inflated balloon is deflated and then inflated again, the “activated” balloon becomes even easier to inflate.

  The elastomeric polymer used in the film and method of the present invention may be any extrudable elastomeric polymer. Examples of such elastomeric polymers include block copolymers of vinylarylenes and conjugated diene monomers, natural rubbers, polyurethane rubbers, polyester rubbers, elastomeric polyolefins and polyolefin blends, Examples include elastomeric polyamides. The elastomeric film may consist of a blend of two or more of the types of elastomeric polymers described above. Preferred elastic polymers are block copolymers of vinyl arylenes and conjugated diene monomers such as AB, ABA, ABC or ABCA type block copolymers. Here, the segment A is composed of arylenes such as polystyrene, and the segments B and C are composed of dienes such as butadiene, isoprene or ethylene butadiene. Suitable block copolymer resins are readily available from KRATON Polymers of Houston, TX or Dexco Polymers LP of Planchemin, LA.

  The elastomer film portion of the present invention may be a single layer film made of an elastomer polymer. The elastomer film of the present invention may be a multilayer film. Each layer of the multilayer elastomeric film may be composed of elastomeric polymers, or a plurality of layers may be composed of an elastomer or a non-elastomeric polymer of thermoplastic resin, either alone or in combination in each layer. The only limitation is that at least one layer of the multilayer elastomeric film must contain an elastomeric polymer and the multilayer elastomeric film as a whole must be an elastomeric film. When the elastomer film is multi-layered, the one or more layers may be composed of an extensible polymer and / or a brittle polymer.

  The elastomer film of the present invention may contain other components such as a component for improving film properties, a film processing aid, and a film appearance improving agent. These additional components may be the same or different in each layer present. For example, polymers such as polystyrene homopolymer or high impact polystyrene can be blended with the elastomeric polymer in the film to stiffen the film and improve the strength properties of the film. . Viscosity reducing polymers and plasticizers can be added as processing aids. Other additives such as pigments, dyes, antioxidants, antistatic agents, slip agents, foaming agents, heat and / or light stabilizers, and inorganic and / or organic fillers can be added. Each additive can be present in one or more or all layers of the multilayer film.

  The elastomer film of the present invention can be prepared by any film forming method. In particular embodiments, extrusion methods such as cast extrusion or blown film coextrusion are used to form the elastomeric film. A method for extruding a film by a casting method or a blow method is known. A method for co-extrusion of a multilayer film by a casting method or a blow method is also known.

  After the film is extruded, it is cooled and solidified. The film can then be activated, drilled, laminated with adhesive to other materials, cut, or other processing steps.

  However, before winding, a thin layer of coating in a carrier solvent such as ink, lacquer, surfactant, lubricant, or slurry is applied to the surface of the elastomeric film to prevent blocking. While not wishing to be bound by theory, we believe that this surface coating prevents blocking by one or more mechanisms. First, we believe that the coating forms a thin layer on the surface, thereby providing a physical barrier between the sticky surfaces of the film. Secondly, it is believed that the coating adsorbs or bonds to the surface of the film, thereby reducing the film surface tack and tendency to block the surface material.

  Water is a preferred carrier solvent for the coating. Water-based inks, lacquers, lubricants, surfactant solutions, and slurries are known in the art. Carrier solvents other than water, such as isopropyl alcohol, hexane, or ethyl acetate, can be used as coating solvents. Inks, lacquers and lubricants in non-aqueous solvents are known in the art. However, water is the preferred solvent in this method because of problems such as environmental impact, solvent odor, safety concerns, and processing issues.

  The coating is applied to the extruded film by any means that creates a thin layer on the film surface. The coating can be printed on a film, which uniformly deposits a thin film of liquid across the surface. Another means of applying the coating is by spraying a fine mist of liquid onto the film. The coating can be applied by a known means such as a knife coater, curtain coater, sponge-type roll, dip coat roll, brush roll, or other liquid coating on the surface.

  Flexographic printing is one embodiment of a method for applying a thin layer of a coating to a film, as shown in FIG. In the illustrated method, the polymer film layer 12 is melt extruded from a film forming die 18 and falls into the nip between the illustrated rubber roll 13 and metal roll 14. The metal roll can be cooled to quench the molten polymer film. Moreover, when the embossing pattern is desired for the production | generation film, the metal roll 14 may be carved the embossing pattern. The extruded film passes through a flexographic printing station after cooling and solidification. This station includes a stamped plate (flexographic plate) 20 attached to a roll 22, an anilox roll 24, and a coating storage device 26. The paint pattern is on the raised stamped plate 20. Next, the stamp plate is mounted on the roll 22. The coating solution is applied to a stamped plate provided with an anilox roll 24 for picking up the coating from a coating storage device 26 such as a tray, and the coating is transferred to a raised portion of the stamped plate 20. The stamp 20 is then rotated over the material 12 for printing. If desired, a drying unit 40 can be used after application of the coating to accelerate drying of the carrier solvent on the surface of the printed material 12 'and / or curing of the coating.

  In another embodiment of the method of the present invention, a spray coating process is used to apply a thin layer of coating to the film. Such spray painting methods are well known. FIG. 2 shows a typical spray coating method. The polymer film layer 12 is melt-extruded from the film forming die 18 and falls into the nip between the rubber roll 13 and the metal roll 14 shown in the figure. The metal roll can be cooled to quench the molten polymer film. Moreover, when the embossing pattern is desired for the production | generation film, the metal roll 14 may be carved the embossing pattern. The extruded film, after cooling and solidification, passes through a spray coating station where the coating solution is applied onto the film by the spray unit 30. The film can be supported by the back roll 31 or other support surface during the spray coating process. The painted film 12 'is then optionally passed through a heating or drying unit 40 for drying of the carrier solvent and / or curing of the coating.

  In another embodiment of the method of the present invention, knife coating is used to apply a thin layer of coating to the film. FIG. 3 shows a typical knife coating method. The polymer film layer 12 is melt-extruded from the film forming die 18 and falls into the nip between the rubber roll 13 and the metal roll 14 shown in the figure. The metal roll can be cooled to quench the molten polymer film. Moreover, when the embossing pattern is desired for the production | generation film, the metal roll 14 may be carved the embossing pattern. After cooling and solidifying, the extruded film passes through a knife coating station consisting of a back roll 31, a metering dispenser 32, a thin knife 36, and a knife holder 38. The metered paint dispenser 32 deposits a portion of the coating solution or slurry 43 on the moving film 12. The coating solution 34 is then spread with a knife 36 in a thin layer across the film. The knife 36 controls the thickness of the coating layer and flattens the coating surface. The painted film 12 'is then optionally passed through a heating or drying unit 40 for drying of the carrier solvent and / or curing of the coating.

  In another aspect of the method of the present invention, curtain coating is used to apply a thin layer of coating to the film. FIG. 4 shows a typical curtain coating method. As shown in the drawings, the polymer film layer 12 is melt-extruded from the film forming die 18 and falls into the nip between the rubber roll 13 and the metal roll 14 shown in the drawing. After being cooled and solidified, the extruded film passes through a curtain coating station comprising a curtain coater 42 and a back roll 44. In the curtain coating method, the coating (paint) 34 is measured in a curtain coater 42. The weighed coating 34 then falls smoothly like a waterfall from the lip of the curtain coater 42 and flows in layers on the moving film 12 surface. As the coating 34 is deposited on the moving film 12, it is pulled into a thin coating. The painted film 12 'is then optionally passed through a heating or drying unit 40 for drying of the carrier solvent and / or curing of the coating.

  In another embodiment of the method of the present invention, a roll coating method is used to apply a thin layer of coating to the film. FIG. 5 shows a typical roll coating method. As shown in the drawings, the polymer film layer 12 is melt-extruded from the film forming die 18 and falls into the nip between the rubber roll 13 and the metal roll 14 shown in the drawing. After being cooled and solidified, the extruded film passes through a roll coating station comprising a coating pickup roll 50, a coating roll 52, a back roll 54, and a coating storage device 56. The coating solution is picked up by a pick-up roll 50 from a coating storage device 56 such as a tray. The pick-up roll 50 transfers the coating (paint) to the painting roll 52. The paint roll 52 then rotates over the moving film and deposits the coating solution on the surface of the film. The painted film 12 'is then optionally passed through a heating or drying unit 40 for drying of the carrier solvent and / or curing of the coating.

  In FIG. 5, the pick-up roll 50 and the paint roll 52 are shown as rolls having hard and smooth surfaces that transfer the coating (paint) from the container 56 to the film 12. However, for purposes of this disclosure, the pick-up roll 50 may have a sponge-like surface, a bristle or brush-type surface, an engraved surface, or other surface suitable for transferring a coating solution to the film. .

  In these drawings, an optional drying unit 40 is illustrated. However, for some coatings, it may be undesirable to dry or cure the coating's carrier solvent before winding. Such coatings can optimally prevent blocking when the carrier solvent moisture remains. In this case, the drying unit 40 is unnecessary.

  After the elastomeric film is applied, the film can be wound and stored on a roll, even at high temperatures such as an unair-conditioned storage. After weeks to months of storage, the elastomeric film can be easily rewound for further processing and / or incorporation into other products.

  The coated elastomeric film can proceed to further processing, whether immediately after being manufactured and painted, or after being wound and stored. This process includes drilling; cutting; laminating to other substrates such as nonwovens by heat, adhesives or ultrasonic means; activating elastomers; or sheets, ribbons of the film to end use products such as clothing and diapers. Or, it is possible to incorporate a patch, but it is not limited to such an action. It should be understood that these processing steps and other additional processing steps are within the scope of the present invention.

  If the coating is of the type that prevents blocking while wet, removing the residual carrier solvent from the surface of the film after storage of the film and before the film is subjected to additional steps Will be important. Surprisingly, the inventors have found that when the film is rewound, the residual carrier solvent evaporates easily and quickly from the surface of the film. In many cases, no additional assistance, such as surface heating, is required to remove the carrier solvent. However, if the process requires it, the film can be passed through a heating station prior to additional processing steps to help the film dry immediately.

  As an example of additional processing, the non-blocking elastomer film can be activated by known stretching means. Machine direction orientation (MDO) can be used to activate the elastomeric film in the machine direction, while tentering is used to activate the film in the transverse direction. A particularly preferred method of activation of the coated elastomeric film is an incremental stretching that incrementally stretches the film between groups of intermeshing rolls as disclosed in US Pat. No. 4,144,008. It is. The incremental stretch rolls can be used to activate the film in the machine direction, width direction, diagonal direction, or a combination thereof.

In another example of the additional process, the non-blocking coated elastomer film of the present invention can be laminated with the base material layer by a known laminating method. The substrate layer can be an extensible sheet-like material such as other polymer film, cloth, or paper. In one non-limiting example, the substrate layer is a nonwoven web. Examples of suitable nonwoven webs include spunbonded, carded, melt-blown, and spunlaced nonwoven webs. These nonwoven fabrics are composed of fibers such as polyolefins such as polypropylene and polyethylene, polyesters, polyamides, polyurethanes, elastomers, rayon, cellulose, copolymers thereof, or blends or mixtures thereof. Paper products such as cellulosic or tissue-like products comprising cellulosic fibers formed into a mat can be considered non-woven fiber webs or materials that fall within the scope of the present invention. Nonwoven webs may consist of fibers that are homogeneously structured, or may be composed of bicomponent structures such as sheath / core, side-by-side, sea islands, and other known bicomponent shapes. For a detailed description of nonwoven materials, see “Nonwoven Fabric Primer and Reference Sampler”, E.C. A. See Vaughn, Non-woven Industries Association, 3rd edition (1992). Such nonwoven fiber webs typically have a basis weight of about 5 g / m ² to 75 g / m ² . For the purposes of the present invention, the nonwoven material should be very light with a basis weight of about 5 g / m ² to 20 g / m ² . However, heavier nonwoven materials having a basis weight of about 20 g / m ² to 75 g / m ² are also desirable to achieve certain properties such as a comfortable fabric in the resulting laminate or end use product.

  Also, other types of base material layers such as woven fabrics, knitted fabrics, scrims, and net products are also within the scope of the present invention. These materials can certainly be used as a protective layer that prevents the elastomeric film layer from blocking during winding. However, non-woven fabrics are generally preferred for laminates in the method of the present invention because of cost, availability, and ease of processing.

  The non-blocking coated elastomer film of the present invention can be laminated on the base material layer by a known laminating means. These lamination methods include extrusion lamination, adhesive lamination, thermal bonding, ultrasonic bonding, calendar bonding, point bonding, laser bonding, and other means. Combinations of these joining methods are also within the scope of the present invention.

  The non-blocking coated elastomer film of the present invention can be laminated on two or more of the base material layers.

  When the non-blocking coated elastomer film of the present invention is laminated with a non-elastomeric substrate, the laminate must be activated in order to be stretchable and recoverable. Laminates of elastomeric films and fabrics are particularly suitable for activation by incremental stretching. As disclosed in commonly assigned patent 5,422,172 ("Wu'172") (incorporated for reference), elastomeric laminates of the type made here are described herein. It can be activated by incremental stretching using a group of incremental stretching rolls.

  The non-blocking coated elastomeric film of the present invention can be laminated with one or more substrate layers at any point in the process. In particular, the film can be laminated to the substrate layer before or after activation of the film. In the case of most non-elastomeric substrate layers, it is desirable to perform lamination prior to activation and then activate the laminate. Alternatively, activate the non-blocking painted elastomer film, laminate the substrate to the activated non-blocking painted elastomer film, and then activate the laminate once more so that all layers of the laminate are easily stretched. Can be made. If the activated film is laminated to a non-elastomeric substrate and activation after lamination is not desired, the non-elastomeric substrate can be necked, creased, wrinkled, folded, The film components of the laminate can be stretched without bringing together or otherwise treating the second substrate.

  The non-blocking coated elastomeric film or laminate can be slit into strips or cut into sheets or patches and laminated with adhesive, heat, or ultrasound at one or more locations on the end use product.

  The non-blocking coated elastomeric film or laminate can be pierced or punched to provide airflow and breathability to the film or laminate. Specific examples of methods for drilling the film or laminate include, but are not limited to, chemical etching, laser drilling, vacuum drilling, needle punching, calendar punching, ultrasonic drilling, and other known methods.

  The following examples are presented to illustrate various features of the invention. These examples are in no way intended to limit the invention.

Example 1
An elastomer film of the present invention was prepared and tested for roll blocking. The elastomer film consists of about 50% styrene-isoprene-styrene (SIS) block copolymer (Vector® 4111 from Dexco Polymers LP), 25% styrene-butadiene-styrene (SBS) block copolymer [Dexco Vector (R) 7400 from Polymers LP], 20% anti-block masterbatch (Lehmann & Voss 9840; about 50% anti-blocking agent in Dow STYRON (R) 485 polystyrene carrier resin 2% slip masterbatch (9841 from Lehmann &Voss; about 20% erucamide slip agent in Dow STYRON® 485 polystyrene carrier resin), and 3% white masterbatch concentrate [Schulman Corporation Schulman (registered trademark) 8500]. The film was prepared on a cast extrusion line and the target basis weight was about 70 g / m ² . A mist of Polywater® A (aqueous surfactant solution) was sprayed on one side of the film. The other side of the elastomer film was not treated with a surfactant. The film was then wound up and stored at room temperature for about 1 week.

  After storage, the film was all rewound to determine if significant blocking had occurred. The film could all be rewound without causing serious blocking problems.

Example 2
An elastomer film of the present invention was prepared and tested for roll blocking. The elastomer film consists of about 45% styrene-isoprene-styrene (SIS) block copolymer (Vector® 4111A from Dexco Polymers LP), 30% styrene-butadiene-styrene (SBS) block copolymer [Dexco Vector® 7400 from Polymers LP, 15% impact polystyrene (Dow STYRON® 478), 2% slip masterbatch (9841 from Lehmann &Voss; Dow STYRON® 485 polystyrene carrier About 20% erucamide slip agent in the resin] and 5% white masterbatch concentrate (Schulman® 8500 from Schulman Corporation). The film was prepared on a cast extrusion line and the target basis weight was about 70 g / m ² . One side of the film was painted by printing a lacquer (PE-081505A from Flint Ink, Ann Arbor, Mich.) Dissolved in an organic solvent mixture by a flexographic press using a standard full-scale dot printing pattern. The coating was applied so that a coating thickness of about 0.4 μm was obtained. The other side of the film was not painted.

  The coated elastomer film was wound on a roll and stored at room temperature for 5 days. After storage, the film was completely rewound to determine if it caused significant blocking. The film could be completely rewound with little or no blocking. The film was then rewound and stored at room temperature for an additional 15 days. Again, after this aging, the elastomeric film could be easily rewound.

  The specific illustrations and embodiments described herein are merely exemplary in nature and are not intended to limit the invention as appropriate by the claims. Further embodiments and examples will be apparent to those skilled in the art in view of this specification and are within the scope of the claimed invention.

FIG. 1 is a schematic diagram of a typical flexographic printing or painting method. FIG. 2 is a schematic view of a typical spray coating method. FIG. 3 is a schematic view of a typical knife coating method. FIG. 4 is a schematic view of a typical curtain coating method. FIG. 5 is a schematic view of a typical roll coating method.

Explanation of symbols

12 Polymer Film Layer 12 ′ Non-blocking Painted Elastomer Film 13 Rubber Roll 14 Metal Roll 18 Film Forming Die 20 Engraving Plate 22 Roll 24 Anilox Roll 26 Coating Storage Device 30 Spray Unit 31 Back Roll 32 Metering Paint Dispenser 34 Coating Solution or Slurry 36 Knife 38 Knife holder 40 Drying unit 42 Curtain coater 44 Back roll 50 Paint pick-up roll 52 Paint roll 54 Back roll 56 Coating storage device

Claims (38)

  A non-blocking coated elastomer film comprising an elastomer polymer film layer and a non-blocking solvent-based coating layer containing a non-blocking coating component, wherein the coating layer is coated on a first surface of the elastomer polymer film layer.   The non-blocking coating elastomer film according to claim 1, wherein the non-blocking solvent-based coating component is selected from the group consisting of ink, lacquer, surfactant, lubricant, slurry, and combinations thereof.   The coating of the non-blocking solvent-based coating layer on the elastomer polymer film layer is selected from the group consisting of printing, spray coating, knife coating, curtain coating, dip coating, roll coating, sponge roll coating, and brush roll coating. The non-blocking paint elastomer film according to claim 1.   2. The non-blocking coated elastomer film according to claim 1, wherein the non-blocking solvent-based coating layer is applied to the elastomer polymer film layer in a pattern composed of spaced coating regions separated by a non-coating surface region. .   The non-blocking solvent-based coating layer is applied to the elastomeric polymer film layer in a pattern comprising a substantially continuous coating region surrounded by a substantially discontinuous region of the non-coating surface. The non-blocking coated elastomeric film according to claim 1.   The non-blocking solvent-based coating layer is applied to the elastomeric polymer film layer in a pattern comprising a substantially continuous coating region having substantially no non-coating surface region. Non-blocking painted elastomer film.   The elastomer polymer film layer comprises block copolymers of vinylarylenes and conjugated diene monomers, natural rubbers, polyurethane rubbers, polyester rubbers, elastomeric polyolefins, elastomeric polyamides, and these 2. The non-blocking coated elastomer film according to claim 1, comprising an elastomer polymer selected from the group consisting of:   The non-blocking coated elastomer film according to claim 7, wherein the elastomer polymer film layer is composed of a blend of an elastomer polymer and a high impact polystyrene.   2. The non-blocking coated elastomer film according to claim 1, wherein the elastomer polymer film comprises a multilayer elastomer film layer.   The non-blocking coated elastomer film according to claim 1, wherein the coating layer is dried.   The non-blocking coated elastomeric film according to claim 1, further comprising activation of the painted elastomeric film.   The non-blocking coated elastomeric film according to claim 11, wherein the coated elastomeric film is activated by stretching.   The non-blocking coated elastomeric film according to claim 12, wherein the coated elastomeric film is activated by a method selected from the group consisting of incremental stretching, machine direction orientation, tentering, and combinations thereof.   2. The non-blocking coated elastomer film according to claim 1, wherein a second non-blocking solvent-based coating layer is further applied to the second surface of the elastomer polymer film layer.   The non-blocking coated elastomeric film according to claim 1, wherein the coated elastomeric film is bonded to a base material layer.   The non-blocking coated elastomeric film according to claim 15, wherein the base material layer comprises a polymer film layer, a nonwoven fabric, a paper product, a woven fabric, a knitted fabric, a scrim, a net product, or a combination thereof.   The base material layer and the coated elastomer film are bonded by a method selected from the group consisting of coextrusion, extrusion coating, adhesive bonding, thermal bonding, ultrasonic bonding, calendar bonding, point bonding, and combinations thereof. The non-blocking coating elastomer film of Claim 15.   The painted elastomer film is bonded to a plurality of base material layers, and the plurality of base material layers are made of a polymer film layer, a nonwoven fabric, a paper product, a woven fabric, a knitted fabric, a scrim, a net product, or a combination thereof. The non-blocking coated elastomeric film according to claim 1, comprising at least one substrate selected from the group consisting of:   The non-blocking coated elastomeric film according to claim 1, wherein the non-blocking coated elastomeric film is perforated. a) providing an elastomeric polymer film comprising an elastomeric polymer; and b) coating the first surface of the elastomeric polymer film with a non-blocking solvent-based coating comprising a non-blocking coating component;
A process for producing a non-blocking painted elastomer film comprising:   21. The method according to claim 20, wherein the non-blocking solvent-based coating component is selected from the group consisting of ink, lacquer, surfactant, lubricant, slurry, and combinations thereof.   The non-blocking solvent-based coating is applied to the elastomer polymer film layer by a method selected from the group consisting of printing, spray coating, knife coating, curtain coating, dip coating, roll coating, sponge roll coating, and brush roll coating. The manufacturing method of Claim 20 which paints.   21. The method according to claim 20, wherein the non-blocking solvent-based coating layer is applied to the elastomer film layer in a pattern consisting of spaced coating regions separated by a non-coating surface region.   21. The non-blocking solvent-based coating layer is applied to the elastomeric film layer in a pattern consisting of substantially continuous painted regions surrounded by substantially discontinuous regions of the non-coated surface. The manufacturing method as described.   21. The method according to claim 20, wherein the non-blocking solvent-based coating layer is applied to the elastomer film layer in a pattern consisting of a substantially continuous coating region having substantially no non-coating surface region.   The elastomer polymer film layer comprises block copolymers of vinylarylenes and conjugated diene monomers, natural rubbers, polyurethane rubbers, polyester rubbers, elastomeric polyolefins, elastomeric polyamides, and these 21. The process according to claim 20, comprising an elastomeric polymer selected from the group consisting of:   21. The method according to claim 20, wherein the elastomer polymer film layer comprises a blend of an elastomer polymer and high impact polystyrene.   The method according to claim 20, wherein the elastomer polymer film layer comprises a multilayer elastomer film layer.   The manufacturing method according to claim 20, further comprising a drying step.   The manufacturing method according to claim 20, further comprising an activation step of the painted elastomer film.   The production method according to claim 30, wherein the painted elastomer film is activated by stretching.   32. The method according to claim 31, wherein the coated elastomer film is activated by a method selected from the group consisting of incremental stretching, machine direction orientation, tentering, and combinations thereof.   The manufacturing method according to claim 20, further comprising a step of coating the second surface of the elastomer polymer film layer with a second non-blocking solvent-based coating layer.   The manufacturing method according to claim 20, further comprising a step of bonding the painted elastomer film to the base material layer.   The manufacturing method according to claim 34, wherein the base material layer comprises a polymer film layer, a nonwoven fabric, a paper product, a woven fabric, a knitted fabric, a scrim, a net product, or a combination thereof.   The base material layer and the coated elastomer film are bonded by a method selected from the group consisting of coextrusion, extrusion coating, adhesive bonding, thermal bonding, ultrasonic bonding, calendar bonding, point bonding, and combinations thereof. 34. The production method according to 34.   Bonding the painted elastomer film to a plurality of substrate layers, wherein the plurality of substrate layers are polymer film layers, nonwoven fabrics, paper products, woven fabrics, knitted fabrics, scrims, network products, or combinations thereof 35. The production method according to claim 34, comprising at least one substrate selected from the group consisting of:   The manufacturing method according to claim 20, further comprising a step of drilling the non-blocking coated elastomer film.

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